PNR RailWorks was the first in North America to use the innovative Edilon Corkelast® embedded rail system, which crews installed in preparation for the arrival of a new coal stacker-reclaimer at Neptune Terminals in British Columbia.

PNR RailWorks installed an embedded rail system (ERS) typically used in European transit applications that features the durable polymer compound, Edilon Corkelast®. A hallmark of the Edilon Corkelast® ERS technique is continuous rail support that optimizes weight distribution to minimize “point loads,” or intense stress, on the rail.

In conjunction with installation of the ERS, crews also worked to improve track layout and expand capacity. They constructed 8,000 feet of embedded and ballasted track with 16 No. 8 turnouts. PNR RailWorks also continue to provide ongoing maintenance and emergency response services.

Unique Features

Neptune Terminals, one of North America’s largest multi-product bulk terminals, relied on PNR RailWorks to replace its aging, wood-tie crane-rail system with a more dependable alternative for its 24-hour-a-day, year-round operations. Neptune sought to reduce high point loads on the track system that led to broken rails and damaged ties. Because of the heavy loads, ties and fasteners broke often, meaning frequent shutdowns for emergency track maintenance.

The ERS provides the needed weight redistribution, replacing ballast, ties and rail-fastening hardware with concrete blocks that have channels for the rail and the surrounding Corkelast® “goo” that hardens to hold the rail in place. The new system facilitates movement of a new $45-million stacker-reclaimer that replaced a smaller, older unit.

The work was completed in multiple phases to allow the existing system to remain operational for as long as possible. To install the ERS, crews followed an elaborate seven-step process. Rails were procured and prepped starting in December 2012. The installation process started in February and was completed in June 2013.